1997-2001 Honda CR250 External Shift Linkage Maintenance Part 2: Inspection

Dec 26, 2016

This is PART 2 of the full step-by-step external shift linkage inspection for your 1997-2001 Honda CR250 Dirt Bike.

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Honda CR250 External Shift Linkage Inspection

Step 9: Inspect the shift shaft.
- Check the shaft for bend or uneven wear.
- Check the shift lever splines for pits or cracks.
- If the spring and snap ring are tight, leave them on the shaft, if they are loose, replace them.
Step 10: Inspect the stopper assembly components.
- Check the stopper arm for bends or cracks.
- Test the stopper wheel for smooth operation.
- Check the stopper spring for tension, fractures or uneven wear.
- Ensure the washer is still flat and smooth.
Step 11: Inspect the shifter drum and center pin.
- Check the center pin for bends and the threads for stripping.
- Check the drum for signs of excessive wear. If any parts of the drum are worn, it will not operate properly.
Step 12: Inspect the guide plate and drum shifter components.
- Check the pawls, springs, plungers and drum shifter body for wear. If these components are worn in any way they will need to be replaced.
- Check the guide plate for warping, cracks, or any signs of fatigue.
Step 13: Assemble the drum shifter.
- Install the plunger and spring into drum shifter body.
- Install the pawl with the round end in the drum shifter body, make sure the groove pushes against the plunger.
- Repeat on the opposite side.
- Install the drum shifter into the guide plate, the drum shifter assembly should not move with the pawls extended.